Dry drilling and core acquisition system

ABSTRACT

A rotary dry drilling system comprises a surface mounted drill having a drill bit and a drill bit driver rotationally connected by a hollow drill string. There is included core sample capture means adapted to travel from the head of the drill string to the tail of the drill string. The system also comprises an auger for removing cuttings from a comminution zone and cuttings fluidization means to facilitate transport of cuttings from the comminution zone to the auger. Once the cuttings are removed by the auger they are collected and transported to the surface for disposal.

CROSS-REFERENCE TO OTHER APPLICATIONS

The present application is a continuation-in-part of our U.S. patentapplication Ser. No. 11/746,626 filed in the USPTO on May 9, 2007.

FEDERAL FUNDING

N/A.

FIELD OF THE INVENTION

The present invention relates generally to the field of core boring andmore particularly to a dry drilling and core capture device.

BACKGROUND OF THE INVENTION

Traditional sample recovery systems rely heavily upon the use of waterto flush the cuttings away from the rock/bit interface or comminutionzone. Water pressure is also used to deliver the core capture device tothe bottom of the hole and allows the dogging mechanism to latchproperly. This technology only works on consolidated material.Unconsolidated materials would normally be flushed away from the holethus preventing the capture of a sample.

Lunar drilling will be a dry drill scenario. Fluids will not likely beavailable to flush away the cuttings from the comminution zone.Additionally, there is a desire to capture unconsolidated materialrather than flush it away. Thus conventional drilling cannot be used.

There is a need for an apparatus that permits dry drilling and corecapture in environments where fluid will not likely be available.

SUMMARY OF THE INVENTION

The apparatus of this invention is designed for dry drilling and corecapture and so solves the need stated above. The apparatus is a rotarydry drilling system comprising a surface mounted drill having a drillbit and drill bit driving means rotationally connected through a hollowdrill string to the drill bit for drilling a bore through rock to obtaina core sample of the rock. The drill string has a head and a tail. Thecore sampler is adapted to travel from the head of the drill string tothe tail of the drill string through the hollow drill string to capturethe core sample of rock. There is also included auger means connected tothe drill bit for removing cuttings from the drill comminution zone andtransporting the cuttings up-hole. To ensure that the cuttings movesmoothly up-hole and do not foul the drilling operation there isprovided with the system a cuttings fluidization means connected to thehead of the drill string to facilitate transport of cuttings from thecomminution zone to the auger means. A cuttings management means isconnected to the drill string for collecting and transporting cuttingsto the surface. The core sampler or core capture device comprises arotating gate assembly having a first open position and a second closedposition; a core tube adapted to receive a core sample; an activationtube coaxial with the core tube and surrounding the core tube. Theactivation tube is adapted to mechanically engage the rotating gateassembly thereby moving it from the first open position to the secondclosed position. A screw cap is included and adapted to engage theactivation tube and transmit rotational movement from the drill motor tothe activation tube so that the activation tube is forced intoengagement with the gate assembly. The gate assembly comprises a gateassembly housing fixed to the bottom end of the core tube to house arotating gate body. The rotating gate body comprises a first disc and asecond disc. Each of the discs has an axis and they are co-axial. Thefirst disc and second disc are jointed by a member between therespective rims of the first and second disc.

The invention is more fully understood by referring to the followingdiagrams and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a cross-sectional side view of the down-hole end of a drillstring of one example of the invention.

FIG. 2 is an assembly diagram of the components of the core capturedevice of another example of the invention.

FIG. 3 is a more detailed diagram of the components of the core capturedevice of the example shown in FIG. 2.

FIGS. 4A to 4D illustrate& the activation tube of one example of theinvention.

FIGS. 5A to 5F illustrate views of other components of the invention.

FIG. 5G illustrates the auger tube of one example of the invention.

FIG. 6 illustrates the bottom portion of the core capture tube in oneexample of the invention.

FIG. 6B illustrates the core capture device of one embodiment of theinvention.

FIG. 7 illustrates the first and second side plates of one example ofthe invention.

FIG. 8 illustrates major sub-systems of the mechanical control system ofone example of the invention.

FIG. 9 illustrates the wireline component of one example of theinvention.

FIG. 10 illustrates the wireline of the invention.

FIG. 11 illustrates the overshot mechanism of one example of theinvention.

FIG. 12 illustrates the port control mechanism of one example of theinvention.

FIG. 12A illustrates the outer port control sleeve of the example ofFIG. 12.

FIG. 13 illustrates the bailings bucket of one example of the invention.

FIG. 14 illustrates the bailings bucket of the example of the inventionof FIG. 13.

FIG. 15 illustrates the anti-contamination wipers of one example of theinvention.

FIG. 16 illustrates the anti-contamination wipers of the same example ofthe invention as FIG. 15.

FIG. 17 illustrates the location of a second anti-contamination wiper ofone example of the invention.

FIG. 18 shows in exploded view the fluidizer of one example of theinvention.

FIG. 19 illustrates the circular bottom housing of the example of FIG.18.

FIG. 20 illustrates the flat top cap of the example of FIG. 18.

FIG. 21 illustrates the cam of the fluidizer of FIG. 18.

FIG. 22 illustrates the hinge member of the fluidizer of FIG. 18.

FIG. 23 illustrates the hammer of the fluidizer of FIG. 18.

FIG. 24 illustrates the ring member of the anvil of the fluidizer ofFIG. 18.

FIG. 25 illustrates the cam bearing block of the fluidizer of FIG. 18.

FIG. 26 illustrates the spring cap of the fluidizer of FIG. 18.

DETAILED DESCRIPTION OF THE INVENTION The Core Capture Device

FIG. 1 shows a cross-sectional side view of the down-hole end of adrilling string (8) illustrating the core capture device (10)constructed in accordance with one example of the invention. The corecapture device (10) is comprised of a core capture tube (12) containedwithin an activation tube (14) which in turn is contained within anauger tube (16). The core capture tube contains the core capture device.The activation tube transmits forces to activate and deactivate the corecapture device as more fully explained herein. The forces aretransmitted by way of a wire string and clutches through the drillstring. The auger tube carries cuttings from the communition zone up thedrill string and away from the drill bit (18) which is located at theend of the drill string and the auger tube.

The core capture device includes a core capture scoop (20) located atthe down-hole end of the core capture tube (12). The scoop is adapted tocapture a sample of a drill core (24) formed as the drill bit (18)progresses downward into a rock formation (22). As the core growslonger, it moves into the orifice (25) of the drill string and into thecore capture device (20). Sensors on the drill string are able tomeasure just how much core is available for capture and when the corecapture device should be activated.

FIG. 2 is an assembly diagram of the components of the core capturedevice (10), the core capture tube housing the core capture device andthe activation tube. The core capture tube (12) consists of a lowerhousing portion (24) attached below an upper portion (26). The lowerhousing portion (24) houses the core capture device (10). Placed overthe core capture tube (12), and in mechanical communication with thecore capture device is the activation tube (28) composed of a bottomportion (30) and an upper portion (32). An activation cap (34) is fixedto the upper end (36) of the upper portion (32) of the activation tube.

FIG. 3 is a more detailed diagram of the components comprising the topend assembly (38) of the core capture device. The components are shownin a transparent view so that their inner features are illustrated andan appreciation of how they are assembled can be gained. The componentsof the top end assembly (38) consist of the core capture tube upperportion (26) over which is placed the upper portion (32) of theactivation tube. The activation cap (34) is placed over the top end (40)of the activation tube upper portion (32). The top end (42) of the corecapture tube upper portion (26) ends in a cylindrical projection (44)having a threaded aperture (46) angled inward at its centre. As can beseen from the dashed transparency lines, the core capture tube upperportion (26) is adapted to fit within the upper portion (32) of theactivation tube such that the lower bell portion (50) of the corecapture tube upper portion fits within the first void (52) of the upperportion of the activation tube (32). The cylindrical upper section (54)of the core capture tube upper portion (26) passes through the firstvoid (52) and second void (56) of the upper portion (32) of theactivation tube and into the first void (58) of the activation cap (34).The first void (58) of the activation cap is separated from the secondvoid (60) of the activation cap by a throat (62) into which the insidethreaded cylindrical projection (44) is set. In its assembledconfiguration, the top portion (64) of the upper portion of theactivation tube (32) is set within the first void (58) of the activationcap (34) so that the top end (40) of the activation tube upper portionabuts against the inner top surface (66) of the first void (58) of theactivation cap. In its assembled configuration the top end (40) of thecore capture tube upper portion (32) abuts against the upper innersurface (66) of the first void (58). To avoid wear, washer (68) isplaced on the top end (42) between it and the inner surface (66). In oneembodiment of the invention the washer (68) is made from bronze. Insidethreaded cylindrical projection (44) is disposed within throat (62) sothat the top end (70) of the projection (44) is above the bottom surface(72) of the second void (60) of the activation cap. At least one washer(74) and perhaps two washers (74) and (76) are placed over theprojection and a cap screw (78) is used to fix the activation cap (34)to the core capture tube. In one embodiment of the invention the washersare made of bronze.

FIG. 4 shows four views: A (side—partial cut away), B (bottom end), C(bottom perspective) and D (top perspective) of the upper portion (32)of the activation tube. The upper portion (32) of the activation tubehas a top section (64) and a bottom section (82). The top section (64)has an outside diameter (86) that is wider than the outside diameter(84) of the bottom section (82). The height (90) of the top end isshorter than the height (92) of the bottom end.

FIGS. 5A to 5D there are shows four views—A (side view), B (top view), C(perspective view) and D (bottom view) of the bottom portion (30) of theactivation tube. The bottom portion (82) of the upper portion (32 inFIG. 4) of the activation tube has a bottom threaded end (94) adaptedfor engagement with the threaded portion (100) of the top end (80) ofthe bottom portion (30) of the activation tube. The void (98) isconfigured so that the top end (80) of the bottom portion of theactivation tube (30) fits within space (102) and the top edge (104)abuts against interior shoulder (106) of space (102). Void (98) andthroat (110) are dimensioned to accept the upper portion (26) of thecore capture tube (26 FIG. 2). The top end (80) of the bottom portion(30) is threaded to permit secure attachment to the bottom (94) end ofthe top portion (32) of the activation tube. Below the top end (80) area middle interior section (111) and a bottom interior section (112). Themiddle and bottom interior sections are configured to accept the lowerportion (24) of the core capture tube that contains the core capturedevice (10). The bottom section (112) of the lower portion of theactivation tube includes a first guide way (114) and a second guide way(116). These guide ways are mechanically linked to first and second lugson the sampling gate of the core capture device within the bottomportion of core capture tube as more fully explained below.

FIG. 5B shows two views—A (assembled) and (B) cross-section of theactivation tube (28) of the invention comprising the lower portion (30)and the upper portion (32) and the activation cap (34). Thecross-sectional view (B) illustrates the core capture tube (1 2)containing the core capture device (10). Attached to the top end of theactivation cap is the bailings bucket (302) which is more fullyillustrated and explained below.

FIG. 5G shows two views of the auger tube (500) of the invention in sideview (A) and cross-sectional view (B). The activation tube is set withinthe auger tube. Cuttings from the bit end (504) are forced up the drillhole and away from the bit by the rotational action of the auger tube.Once the cuttings reach the up-hole end (502) of the auger tube they areforced into the bailings bucket as more fully explained below.

FIG. 6 shows a detailed view of the bottom portion (24) of the corecapture tube which contains the core capture device (10). The bottomportion (24) is comprised of an upper connecting section (1 20) a middlecylindrical section (122) and a lower housing (124). The upperconnection section (120) is adapted to connect to the lower portion (50)of the upper portion (26) of the core capture tube (12). In oneembodiment of the invention the connection means is a threaded coupling.The middle cylindrical section (122) is adapted to contain a core sampledrilled by the drill bit. The lower housing (124) is adapted to housethe scoop (125) and scoop activation mechanism. The scoop consists of afirst circular plate (126) and a second circular plate (128) in parallelspaced arrangement. Between the two plates is a scoop member (130), asemi-circular member having the same radius as the first and secondplates. The scoop pivots from a first open position to a second closedposition around an axis (132). The scoop also incorporates a first lug(not shown) and an opposite second lug (not shown) projecting from thefirst and second side plates respectively. These lugs are adapted toengage the first (114) and second (116) guide-ways respectively of thelower portion of the activation tube (FIG. 5A). The scoop is mountedbetween a first (140) and second (142) side plate in a pivotingrelationship so that the first lug engages the first guide-way and thesecond lug engages the second guide-way. The axis (132) pivots aroundpivot points (144) and (146) on the side plates. The side plates aremounted by mounting means in the form of screws or rivets to the flatoutside surfaces (148) and (150—not shown) of the lower housing (124).

FIG. 7 shows a first and second side plate (152) of one embodiment ofthe invention. Each side plate is generally a rectangular plate havingeach of its corners (154) cut to 45 degrees. There are four apertures(156) for fixing the side plate to the lower housing. A fifth aperture(158) is adapted for mounting the scoop in a pivoting relationshipbetween the first and second side plates. The outline of the scoop isshown as line (160). The guide-way (162) is adapted to accept a lug(134) or (136) in a sliding relationship between a scoop first openposition (166) and a scoop second closed position (168). The radius oftravel of the lugs is shown by line (170). A first (174) and second(176) alignment pins on the inside face of the side plates are adaptedto fit within alignment holes on the outside surface of the lowerhousing. In operation, the guide ways (114) and (116) (FIG. 5A) areengaged with lugs (134) and (136) respectively. In order to move thescoop from its first open position to its first closed position, thelower portion of the activation tube is moved downwards which rotatesthe scoop in a clock-wise movement. This causes the scoop to cut thecore sample within the lower core capture tube capturing the core in thescoop. To maintain the scoop in the open position, the lower portion ofthe activation tube is moved upwards so that the guides pull the lugs upand rotate the scoop to its open position. The invention accomplishesthis movement of the activation tube by way of a mechanical controlsystem further described below.

FIG. 8 shows the major sub-systems to the mechanical control system usedto control the core capture device. These are the wire string (200), theswivel clutch (202), dogging & swivel clutch (204) and the samplecollection bucket also known as the bailings bucket (206). The wirestring is inserted down-hole through the hollow drill string and is usedto activate and de-activate the core sampling scoop and the cuttingsmanagement system which includes the bailings bucket and the portcontrolling entry to the bailings bucket.

The wire line mechanism (200) is an integral part of the entire samplecapture device. The wireline delivers the sample capture device to thebottom of the hole and it activates the opening and closing of thesampling scoop. Once the sample capture device is in place, operationalsequences allow the wireline to move from controlling the opening andclosing of the scoop to opening and closing of the bailings bucket port.Once these operations are complete, the wireline disengages, by means ofa clutch mechanism, and allows the sampling device and port opening torotate freely with the drill string while the wireline stays stationary.

As the drill completes a drilling cycle (has drilled a sample), thewireline re-engages and closes off the bailings bucket ports, thuspreventing any loose material entering the inside of the drill string.Following port closure, the wireline re-positions itself to facilitatethe closure of the gate on the sample capture device, thus capturing thesample. The sample capturing device is capable of capturing a sample ofconsolidated or unconsolidated material.

Once the sample has been secured, the wireline hoists the entirebailings bucket and sample capture device mechanism to surface, wherethe captured sample or cuttings from the bailings bucket may be furtherprocessed or disposed of as required.

The wire line is required to:

(1) impart thrust to facilitate the collapse of the spring activatedcomponents;

(2) be capable of handling the retraction forces required to break aconsolidated sample, release the springs and to lift the core capturedevice up the drill string;

(3) be flexible enough to allow the wireline to be coiled on surfaceduring retrieval and stowed sequences; and,

(4) be rigid to allow rotational forces to be transmitted when in theextended locked position.

The wireline configuration has a first retracted position and a seconddeployed position. In its retracted position, the wireline can be coiledonto a spool where it awaits deployment. Once activated, the wireline ispulled off the spool into a deployed position down the drill string.Once the core capture device has contacted the bottom of the hole, thewireline is mechanically locked together by a pin system illustratedherein.

Referring to FIG. 8 and FIG. 9, the wireline comprises a plurality ofvertebra-like members (210) serially joined. The individualvertebra-members are shown in FIG. 9. Each member has a Y-shaped body(211) composed of a leg member (212) and two arm members (214) and(216). Each of the arm members is composed of a section (218) and (219)angled outwards from the leg member and a straight section (220) and(221) parallel to the leg member. Proximal to, and just above the bottomend of the leg member is a first elongated aperture (not shown) and asecond adjacent elongated aperture (not shown) adapted to engage a firstpin (228) and a second pin (230) in a pivoting and sliding relationship.The first pin and the second pin are located on the inside surfaces ofeach of the straight sections (220) and (221). The vertebrae areserially joined by the aforementioned pins and apertures to form thewire line that can be coiled onto a storage drum when not deployed downthe drill string. Depending from the bottom end of the vertebra memberis a third pin (240) which is adapted to fit within aperture (242)located between the two arm members (214) and (216). In the illustratedembodiment, the vertebra-members include a first (244) and second (246)apertures for weight saving.

Referring to FIG. 8, the wire string has a first compressed operatingmode (250) wherein each of the third pins (240) are engaged in theirapertures (242) and each of the first (228) and second (230) pins are attheir bottom position in the elongated apertures.

FIG. 10 shows a plurality of members in two modes: separated (252),andjoined (254 & 256).

Referring to FIG. 8, the wireline (200) is connected to an overshotmechanism consisting of the clutch assemblies (202) and (204) adapted todeliver the sampling device to the bottom of the drill string via thewireline and to activate both the bailings bucket port control and thescoop of the sample capture device. In addition, the overshot mechanismmust keep the entire sample capture device/bailings bucket at the bottomof the hole and allow them to rotate freely while the wireline remainsstationary.

Referring to FIG. 8 and FIG. 11, the wireline (200) is attached toclutch mechanism (202) by cap member (260). In turn, cap member (260) isfixed by threading on to swivel housing (266). Clutch shaft (270) topend (271) is held to swivel clutch housing (266) by screw (262) andthrust washer (264). In deployment, the wireline is forced downvertically into the drill string thereby compressing its vertebraetogether and also compressing swivel spring (268) which will allow thefirst swivel clutch (272) to engage into the swivel clutch housing (266)on shaft (270). A slight rotation may be required to engage the clutchpins (276) tensioned by clutch springs (276). When the swivel clutchassembly is engaged, torque from the wireline (200) can be transmittedthrough the overshot mechanism to the bailings bucket port controlmechanism (204) to open or close the ports to the bailings bucket or toopen or close the sampling scoop. When the tension in the wire line isreleased, the vertebrae disengage from each other to an elongatedconfiguration. The first swivel clutch (272) is disengaged by thetension in the spring (268) and the wire line will be stationary whilethe bailing bucket control mechanism and bailings bucket continues torotate during drilling operations.

Referring to FIG. 12, the port control mechanism includes an inner portcontrol sleeve (292) and an outer port sleeve (294). The inner portcontrol sleeve nests inside of the outer port sleeve. The wireline(200), dog clutch (285) and second swivel clutch (300 a) control theinner port control sleeve so that the inner port control sleeve moves ina vertical direction with respect to the outer control sleeve in orderto open and close the ports as more fully explained below.

Referring to FIG. 12A, the outer port sleeve (294) consists of a tubularbody (295) having a top portion (297), a middle portion (299) and abottom portion (301). The top portion and the middle portion have aninside diameter (305) that is adapted to fit the inner port controlsleeve in a sliding relationship. The bottom edge of the inner portcontrol sleeve, when installed into the outer port sleeve, abutsshoulder (307). The middle portion has a plurality of ports (303)adapted to coincide with the ports in the inner port control sleeve soas the inner port control sleeve rotates under the influence of the wireline (200) it is able to close the port access from the inside augerwall to the inside of the bailings bucket. The inside diameter (309) ofthe bottom portion (301) of the outer port sleeve is adapted to fit thesecond swivel clutch (300 a).

FIG. 12B, shows two views, A (side view) and B (top view), of theinternal port control sleeve (292). The sleeve includes a splined topend (291) that is adapted to mesh with the dogs of the dog clutch (285).Within the sleeve (292) are a first set of ports (311) and a second setof ports (313) below the first set in a parallel relationship.

In operation, active port control is incorporated in the upper sectionof the auger mechanism and is in the transition zone. Cuttings from thecomminution zone migrate to the top portion of the auger with the aid ofthe fluidizer which is more fully described below. The outer diameter ofthe port control mechanism above the auger is larger, thereby directingthe cuttings into and through the ports to fall into the bucket fortransport to the surface. The activation of the port control iscompleted via the wireline mechanism. During a drilling sequence, theports are open allowing the cuttings to pass through the port into thebailings bucket. During a bailings bucket extraction cycle, the portsare closed prior to removing the core sampling device and bailingsbucket, thus preventing the ingress of contaminants onto the seatingarea of the sample capture device.

Contaminants at the bottom of the hole would prevent the sample capturedevice from seating properly once it had returned from surface for thenext drilling cycle.

Referring now to FIG. 8 Item (202) and FIG. 11 and FIG. 8 Item (204) andFIG. 12, the clutch mechanism and the bailings bucket port controlmechanism (202) & (204) respectively are shown in greater detail. Thebottom (273) of the clutch shaft (270) is in threaded engagement withthe top end (281) of the dog clutch activation shaft (282). The shaft(282) is covered by a shaft cover (280). First swivel clutch (272) isattached to the dog clutch activation shaft (282). The wireline isforced down the drill string and this compresses the vertebrae to itscompressed mode. In turn, the bailings bucket port control clutch spring(296) and the swivel clutch springs (304) are compressed to engage boththe dog clutch (288) and the second swivel clutch (300 a). Rotating thewireline (200) in a clock wise (CW) direction will open the samplecapture device scoop and also extend the dog clutch (285) into the portsleeve splines (291). The wireline (200) will be moved up verticallyapproximately 15 mm until the dog clutch (285) enter the port sleevesplines (291) and bottom-out on the adapter sleeve shoulder. The secondswivel clutch (300 a) will still be engaged allowing the doggingactivation shaft (282) to open the port control sleeve (292). When theport control sleeve (292) is open the wireline (200) will move upvertically to a point where the second swivel clutch (300 a) isdisengaged. At this point the drilling can be continued.

To capture a sample using the core capture device, the followingprocedure would be used. The wireline (200) would be forced downvertically until the swivel clutch assembly (204) was engaged. Thewireline (200) would then be rotated in a counter clock wise (CCW)direction to close off the port control sleeve (292). When the port isclosed off, the wireline (200) would be forced down vertically until thedog clutch (285) enter the port control sleeve (292) undercut. Thewireline (200) would then continue to rotate in a CCW direction untilthe dogs clutch (285) retracted and the scoop is close off. When thescoop is closed off, the sampling device, bailings bucket, port controland swivel line can then be removed from the drill string.

Cuttings Disposal and the Bailings Bucket

Referring to FIG. 8 and FIG. 13, the bailings bucket (300) is a hollowtube and it is placed in the drill string to collect cuttings beingcarried up the auger tube (500 FIG. 5C) from drilling operations anddispose of them. The amount of cuttings that will migrate up the augerinto the bailings bucket will expand in volume by a factor of up to 4:1.It has been our experience that a 15 mm diameter by 10 cm longconsolidated core will need a 40cm long bailings bucket to hold theamount of cuttings that have migrated up the auger from the comminutionzone. Therefore, the volume of the bailings bucket needs to be at least4 times larger than the sample capture device. Assuming the abovementioned dimensions, when drilling holes 2 meters in depth, the samplecapture device with a 40 cm long bailings bucket will need to beextracted 20 times out of the drill string in order to remove thecaptured core and cuttings. In addition, the port control will also besubjected to 20 complete cycles from fully open to fully close to ensurethe cleanliness of the core capture device seat. Operational decisionswill need to be made to determine the quantity of cuttings and orcore/sample that will be kept for further processing or analysis.Depending on the quantities of material required for the analysis orprocess, it is possible that some of the generated cuttings and/or coremay be deemed waste material and dealt with accordingly.

Referring to FIG. 13 and FIG. 5E, the bailing bucket (300) is shown in adisassembled view and is composed of a hollow tube (302) having a bottomnut (304) to cap the bottom end (305) of the hollow tube in threadedengagement and hinge point (306) mounted at the mouth (308) of thebucket (300). The swivel is a “T” shaped member having a stem (310) anda first (312) and second (314) arms. The arms are placed into apertures(315) and (316) in a pivoting relationship. The top end (318) of thestem (310) has a hinge member (320) adapted for pivoting engagement withthe bottom end (299) of swivel clutch shaft (298 FIG. 12) by way ofapertured member (322). The hinge point (306) above the bailings bucketallows for simple manipulation of the bailings bucket when it reachessurface. The bailings bucket may either be delivered to scienceexperiments or be dumped to a specific location. The hinge permits easyremoval of the cuttings from the bucket by allowing the bucket to betilted and the cuttings dumped.

The sample capture device (10) is connected below the bottom nut (304)so that the bottom section of the bailings bucket is the transition zonebetween the bucket and sample capture device. The bailings buckettransmits the forces of the wireline directly to the sample capturedevice for operation of the scoop allowing a sample to be captured.

In FIG. 14, the bailings bucket (300) is shown in assembled views A, Band C. The core capture device is connected by a threaded connection tothe internally threaded projection (324).

FIGS. 15 and 16 show details of the anti-contamination wiper (330). Theanti-contamination wiper is a flared edged (332) attachment to the topsection of the bailings bucket (302). The lip (334) of theanti-contamination is press-fit into the top of the bailings bucket. Theflared edge (332) sits directly below the active port control thatallows the cuttings to pass through the drill string and fall directlyinto the bailings bucket. The flared edge prevents the cuttings fromfalling between the bailings bucket and the internal section of theauger. Each time the entire core capture system is removed from thedrill string, the anti-contamination wiper scrapes the entire interiorlength of the drill string, thus preventing any cuttings from fallingonto the seat section for the core capture device. Cuttings orunconsolidated material outside the drill string will tend to slump intothe ports. With the active port control mechanism in place, thismaterial will be prevented from entering. When the core capture devicere-enters the drill string, cuttings that cling on the bailings bucketor port control mechanism will not fall below the cuttings bucket,because the bucket's anti-contamination wiper sets rides the entirelength of the drill string. A second anti-contamination wiper (331) maybe located on the bottom of the port control sleeve as illustrated inFIG. 17.

An operating sequence is outlined below for capturing an unconsolidatedsample.

-   -   Position the core capture device gate in an open position while        drilling, allowing the sample to enter into the core capture        device.    -   Permit the sample to fill the core capture tube as indicated by        the drill's penetration sensor.    -   Push the wireline into a closed position (collapsed) to transfer        rotational forces to the core capture device gate.    -   Rotate the drill string to drive the outer activation tube down        over the sample tube.    -   Rotate the core capture device gate 90 degrees into the closed        position, closing off the bottom opening and capturing the        sample.    -   Use the wireline to draw the core capture device, sample and        bailings bucket to surface.

The operating sequence for capturing a consolidated (core) sample isoutlined below.

-   -   Open the core capture device gate to permit the sample to enter        the core capture tube.    -   Fill the sample tube as indicated by the drill's penetration        sensor.    -   Push the wireline into the closed position (collapsed) to        transfer rotational forces to the gate.    -   Rotate the head clamp of the drill string to drive the outer        activation tube down over the sample tube.    -   Commence to close the core capture device gate until the        predetermined forces are exerted on the gate due to its closure        on a core. Torque sensing is used to ensure that the core        capture device is not damaged if it cannot fully close.    -   Permit the core capture device to rotate freely around the core        so that the base of the core is scored by the gate.    -   Stop the rotation and close the gate in order to snap the core        from the rock base.    -   Commence to close the core capture device gate until the        predetermined forces are exerted on the gate due to its closure        on a core. Torque sensing is used to ensure that the core        capture device is not damaged if it cannot fully close.    -   This cycle continues until the gate is fully closed and the core        sample is freed from its base rock.    -   Once the gate is fully closed, the wireline is used to draw the        core capture device, core sample and bailings bucket to surface.

The Fluidizer

In experimentation with the core capture device described above, itquickly became evident that as the auger tube became surrounded by thedrill cuttings, the ability for the auger to continue to move thecuttings up the flights decreased. The auger no longer effectivelytransported the cuttings to the cuttings bucket efficiently and tendedto pack the cuttings within the flights of the auger. As a result, drillpenetration rates dropped significantly. As well, the reaction forceswithin the device started to climb and there was notable heat generationin the auger zone. A further result of cuttings removal degradation wasballing of material on the bit rendering it ineffective.

To prevent bit balling and clumping at the bottom of the drill hole, itwas decided that a cuttings fluidization technique was needed. Testresults of the fluidizer described herein indicated that it increasedthe rate of drill penetration by maintaining the cuttings in a fluidstate so that the auger could easily remove the cuttings fromcommunition zone to the bailings bucket.

The fluidizer works by transmitting an impact through the drillingdevice at a specific frequency. A key requirement for the fluidizer wasa direct variable frequency impacting device, capable of delivering ablow that would reverberate through the entire length of the drillstring to the comminution zone. Previous tests eliminated such conceptsas pinging the side of the drill string or having an electric impactdrill incorporated into the top of the drill. Additionally, thefrequency of the impacts has to be variable, separate and notnecessarily proportional to the rotational speed of the drill string.Drilling through several types of test media required differentrotational speeds to move the cuttings from the comminution zone to theaugers on the bit and up onto the flights of the auger. If therotational speed combined with the impacts of the fluidizer isinsufficient, the cuttings would begin to pack, and render the augerinefficient. The requirement was an electro-mechanical fluidizer capableof providing a significant impact to the drill string without affectingthe other drilling components.

FIG. 18 shows an exploded diagram of the fluidizer (500) with a circularbottom housing (502) and a top flat cap (504). The housing (502)consists of a wall (506) and a bottom surface (508). The bottom surfacehas an aperture (510) adapted to fit an anvil/hammer combination (512)which provides a variable frequency impact to the drill string. Thedrill string (not shown) fits through the centre (524) of theanvil/hammer combination. The top flat cap (504) includes an aperture(514) adapted to fit over the top (516) of the anvil/hammer combination(512). The anvil/hammer combination (512) is housed within the housing(502) and the top flat cap (504) closes over the top surface (518) ofthe housing by a plurality of fasteners placed through apertures (520)in the top flat cap (504) and into apertures (522) along the periphery(524) of the housing. Mounted to the top surface (530) of the top flatcap (504) is a motor and drive assembly consists of a motor (532) and adrive shaft (534) having a top portion (536) extending from the motor toa coupler (538) coupling it to a drive shaft bottom portion (540). Thedrive shaft bottom portion includes a first gear wheel (542) adapted formeshing engagement with a second gear wheel (544). The second gear wheelis fixed to the end of a cam shaft (546) on which a cam (548) ismounted. When the motor is operating, rotational movement is transmitteddown the top portion of the shaft, through the shaft coupling and intothe bottom portion of the shaft where it is transformed from verticalrotation to horizontal rotation by the gear wheels. Horizontal rotationof the cam shaft commits the cam to engage the bottom surface of thefluidizer hammer (550) thereby raising the hammer upwards. Attached tothe top surface of the hammer is a spring (554) that moves freely withinthe spring housing (556). There is a tensioning nut (560) that canincrease or decrease the travel of the spring within the housing therebyadjusting the amount of force that the spring will deliver to thehammer. As the cam rotates on the bottom portion of the fluidizerhammer, the hammer is lifted and the spring is compressed within itshousing. At a certain point, the cam will release the hammer and thespring will drive the hammer downwards to contact the anvil (562). Thiscreates an impact that travels down the length of the drill stinglocated within the centre of the hammer/anvil mechanism therebypermitting fluid motion of cuttings up the auger tube and preventingfouling of the drill bit with cuttings.

FIG. 19 illustrates the circular bottom housing (502) in plan view

(A) and side view (B). The housing has the shape of a cylindrical dishconsisting of a wall (506) and a bottom surface (508). The aperture(510) in the middle of the bottom surface is adapted to permit passageof the drill string and to mount the anvil/hammer assembly. A firstplurality of apertures (570) is adapted to mount the hammer mounts. Asecond plurality of apertures (572) is adapted to mount the cam mounts.A third plurality of apertures (574) is adapted to mount the flat topplate (504) to the top of the housing. A fourth plurality of apertures(575) is adapted to mount the bottom housing to the drill frame so thatpercussions from the anvil and hammer travel down the drill string.Dimensions shown on FIG. 19 are illustrative and exemplary only.

FIG. 20,illustrates the flat top cap (504) in a top view (A) and sideview (B). The cap is circular having a large first aperture (580)adapted to permit the drill sting passage through the top cap. A secondaperture (582) permits passage of the motor shaft and a third aperture(584) permits passage of the spring into the spring housing. A first setof small apertures (586) mounts the motor assembly to the top surface ofthe top plate, a second set of small apertures (588) mounts the springhousing to the top surface of the top plate and a third set of smallapertures (590) mounts the top plate to the housing. The bottom surface(592) of the top plate comprises a flange (594) that seats within thehousing wall and provides a tight seal to the housing to prevent dustingress into the housing.

FIG. 21 shows three views (A, B and C) of the cam (548) mounted to camshaft (546). The second gear wheel (544) is fixed to a first end (600)of the cam shaft for meshing engagement with the first gear wheel.Referring back to FIG. 18, as the cam rotates it lifts the hammer andthen releases the hammer to hit the anvil. The frequency of impacts canbe regulated through motor control.

FIG. 22 shows first hinge member (602) identical to second hinge member(604) for holding the hammer in a pivoting relationship to the anvil.The hinge members are fixed to the bottom surface of the housing plateby way of fasteners penetrating the second plurality of apertures (570)in the bottom surface of the housing and the aperture (606) located ineach of the hinge members. A pin member (607) is mounted between thehinge members through respective apertures (608) and (610) for mountingthe hammer to the hinge. The apertures (608) and (610) are comprised ofa bronze bushing (611) fitted within the apertures to bear the load ofthe hammer in repeated cycles.

FIG. 23 shows plan (A) and elevation (B) views of the hammer (612) witha ring member (614) having a first lug (616) for mounting to the hinges(602) and (604) by way of pin member (606) through hole (607) and asecond lug (618), the top surface (620) of which mounts the spring byway of aperture (622), and the bottom surface (624) which provides anengagement surface for the cam. The dimensions shown in FIG. 23 areexemplary and illustrative only.

FIG. 24 shows plan (A) and elevation (B) views of the anvil (630)comprised of a ring member (632), a cylindrical portion (634) disposedabove the ring and a flange member (636) disposed below the ring. Withinthe flange portion are a plurality of apertures (638) adapted to receivefasters for fastening the anvil to the housing bottom surface.

FIG. 25 shows a front view (A) and a side view (B) of a cam bearingblock (640) of a pair of bearing blocks (640) and (642) that arepositioned on either side of the cam. The bottom of each block isapertured (643) to receive fasteners that fix the bearing blocks to thebottom of the housing through the plurality of apertures (572). Thebearing blocks (640) and (642) are apertured (643) to receive the camaxle, and a bronze bushing (644) is inserted into each aperture to bearthe load of cam movement and loading over many repetitions of anvil andhammer contact.

FIG. 26 shows a top view (A) and a side cross-sectional view (B) of thespring cap (650) comprised of a flange member (652), a cylindricalspring housing (654) disposed above the flange member and an aperture(656) centered in the top (658) of the spring housing.

Although the description above contains much specificity, these shouldnot be construed as limiting the scope of the invention but as merelyproviding illustrations of some of the presently preferred embodimentsof this invention. Thus the scope of the invention should be determinedby the appended claims and their legal equivalents.

1. A rotary dry drilling system comprising: a. a surface mounted drillhaving a drill bit having a comminution zone and drill bit driving meansrotationally connected through a hollow drill string to said drill bitfor drilling a bore through rock to obtain a core sample, wherein saiddrill string has a head and a tail; b. a core sample capture devicedisposed within a core capture tube proximate to the tail of the drillstring, said core capture tube disposed within an activation tube fortransmitting activating and deactivating forces to the core capturedevice by means of a wire line; said core capture device comprising: i.a rotating scoop assembly having a first open position and a secondclosed position; ii. a core tube adapted to receive a core sample; iii.wherein, the activation tube is coaxial with said core tube andsurrounds the core tube; iv. and wherein, the activation tube is adaptedto mechanically engage said rotating scoop assembly thereby moving itfrom said first open position to said second closed position; and, v.the core capture tube further comprising a screw cap adapted to engagethe activation tube and transmit rotational movement from the drillmotor to the activation tube so that the activation tube is forced intoengagement with the scoop assembly; c. an auger tube disposed around theactivation tube and above the drill bit, for removing cuttings from saidcomminution zone; d. a cuttings fluidization apparatus connected to saidhead of the drill string to facilitate transport of cuttings from thecomminution zone to said auger tube; and, e. cuttings management meansconnected to said drill string for collecting and transporting cuttingsto the surface.
 2. The device as claimed in claim 1 wherein the scoopassembly comprises a lower housing fixed to the bottom end of the coretube, said lower housing adapted to house a rotating scoop member. 3.The device as claimed in claim 2 wherein said rotating scoop membercomprises a first disc and a second disc, wherein: a. said first andsecond discs each have an axis; b. the first and second discs areco-axial and joined by a joining member between the respective rims ofthe first and second discs; c. the respective outside surfaces of thefirst and second discs each have fixed thereto a first lug and a secondlug; d. said first lug is mounted between the respective axis of eachdisc of the first and second discs and the respective rim of each discof the first and second discs; and, e. said second lug is mounted to theaxis of each of the first and second discs.
 4. The device as claimed inclaim 3 wherein said lower housing includes a bottom orifice toaccommodate said drill string, a left side orifice and a right sideorifice wherein said left and right side orifices are opposite eachother, and wherein the gate assembly housing receives said gate body. 5.The device as claimed in claim 4 wherein said gate assembly housingfurther comprises: a. a first mounting plate fixed over the leftorifice; b. a second mounting plate fixed over the right orifice; c.wherein said first and second mounting plates each further include acentral aperture for receiving the first and second disc first lugspermitting rotational movement of the gate body about its axis; and, d.wherein the first and second mounting plates respectively furtherinclude a first and second arcuate slots for receiving the first andsecond disc second lugs for guiding the gate body from a first openposition to a second closed position.
 6. The device in claim 5 whereinthe joining member cuts the core sample when the gate body is movingfrom the first open position to the second closed position and enclosesthe core within the core tube.
 7. The system as claimed in claim 1wherein said cuttings fluidization apparatus comprises a shock wavetransmitter for transmitting a shock wave from the top of the head ofthe drill string to the tail of the drill string.
 8. The system asclaimed in claim 7 wherein said shock wave transmitter comprises ahousing mounted proximate to the head of the drill string by an aperturethrough which the drill string passes, wherein said housing comprises acasing having a removeably fixed casing cap for sealing said casing andan inside bottom surface.
 9. The system as claimed in claim 8 whereinthe casing is adapted to contain a flapper having a pinned end and a camend, wherein said pinned end is pivotally pinned to said inside bottomof the casing and wherein said cam end is adapted for cycling up anddown at a variable frequency so that on the down stroke said flapperstrikes said inside bottom surface of the casing thereby sending a shockwave down the length of the drill string.
 10. The system as claimed inclaim 9 wherein said cam end of the flapper communicates with a cam,wherein said cam rotates on an axis and communicates said up and downcycling motion to the flapper cam end.
 11. The system as claimed inclaim 10, wherein the cam is connected to a variable speed motor fordriving the cam rotationally about said axis, and wherein said variablefrequency of flapper movement is regulated by regulating the speed ofthe motor, and wherein the cam end of the flapper is spring biasedagainst the cam.
 12. The system as claimed in claim 11 wherein theflapper is weighted to provide a correct magnitude of shock wave to thedrill string.
 13. The system as claimed in claim 12 wherein the shockwave travels to the tail of the drill string and is transmitted to theauger tube and the drill bit causing the vibration thereof and resultingin the fluidization of the cuttings so that they do not clump, ball,clump or bind to the drill bit or auger tube.
 14. The system as claimedin claim 1 wherein said cuttings management means comprises: a. a bucketfor collecting cuttings from the auger tube and transporting thecuttings to the head of the drill string; b. a port for directingcuttings from the auger tube to the bucket wherein said port has an openposition and a closed position; c. port control means for moving theport from said open position to said closed position and from the closedposition to the open position.
 15. The system as claimed in claim 14wherein said port control means comprises a tube section incorporatedinto the upper section of the auger tube, wherein said tube sectionincludes a first and a second port oppositely disposed proximate to thebottom of the tube section.
 16. The system as claimed in claim 15wherein the bottom end of the tube section sits over the top end of theauger tube so that as cuttings are carried up the auger tube they areforced through the open ports and into said bucket.
 17. The system asclaimed in claim 16 wherein the ports are closed by said port controlmeans so that the bucket can be removed from the bore hole and so thatcuttings do not fall into the centre of the bore.
 18. The system asclaimed in claim 17 wherein port control means comprises a wirelinemechanism having a first deployed configuration and a second storedconfiguration.
 19. The system as claimed in claim 18 wherein said firstdeployed position said wireline is adapted to engage the sample capturedevice and position it in its open position.